Overflow down-draw with improved glass melt velocity and thickness distribution

ABSTRACT

An apparatus for making a glass sheet using overflow fusion down-draw process comprising an inlet assembly having an elliptic cylindrical section coupled to a transition section which is, in turn, coupled to an open end of an open channel of an isopipe, and an overflow fusion down-draw process for making glass sheet. The glass melt flow has a high surface velocity profile conducive to the formation of a glass ribbon over the surface of the weirs and the wedge side surfaces with the desired mass distribution.

This subject application is a continuation and claims the benefit ofpriority to U.S. application Ser. No. 13/279,847 filed Oct. 24, 2011 andto U.S. Provisional Application No. 61/407,963 filed on Oct. 29, 2010the content of which is relied upon and incorporated herein byreference.

TECHNICAL FIELD

The present invention relates in general to glass sheet-making equipmentand method. In particular, the present invention relates to method andapparatus for forming a glass sheet using an overflow fusion down-drawprocess. The present invention is useful, e.g., in making glass sheetsuitable for LCD glass substrates using an overflow down-draw process.

BACKGROUND

Fusion down-draw is a leading technology developed by CorningIncorporated, Corning, N.Y., U.S.A. for making thin, precision glasssheets suitable for use as liquid crystal display (LCD) glass substratesand in other opto-electronic devices. This process is schematicallyillustrated in FIG. 1. A stream of molten glass is introduced into aforming trough 103 called isopipe with end-caps 105 at both ends andhaving two side surfaces converging at a line called root 109 via aninlet pipe 101 coupled to the trough of the isopipe. The glass melt isallowed to flow over both top surfaces of the trough side walls of theisopipe called weirs, down along both side surfaces of the isopipe astwo molten glass ribbons 107, and then join and fuse at the root 109 toform a single glass ribbon 111, which is then drawn down in thedirection 113 and cooled below the root to form the glass sheet withdesired dimension. In the zone below the root, the glass ribbon travelssubstantially vertically downward while being drawn and cooled from aviscous state, to visco-elastic and eventually to substantially elastic.The elastic glass ribbon is then cut into individual glass sheets,subjected to further finishing such as edge rounding and polishing, andthen packaged and shipped to LCD panel makers for use as TFT or colorfilter substrates. Cutting of the glass ribbon at below the isopipetypically involves the scoring of the ribbon surface, followed bybending along the score-line, whereby discrete glass sheets areseparated from the ribbon and then transferred to subsequent steps.

One of the advantages of the fusion down-draw process for making glasssheets is that the surface quality of the glass sheets is high becausethe quality areas thereof were formed in an atmosphere and never toucheda solid material such as the forming equipment. This process has beenused successfully for making glass sheets having a width as large as3000 mm and a thickness of about 0.6 mm.

The size of LCDs for the consumer electronics market has grown steadilyin the past decade, and along with a corresponding demand for higherimage quality. These have fueled the demand of large-width glasssubstrates and posed increasingly more stringent requirements for glasssheet quality, such as edge warp and waviness, sheet warp, surfacewaviness and roughness, thickness uniformity, mura, as well as stress.In addition, consumers have demonstrated interest in lighterelectronics, which call for thinner glass substrates having a thicknessof 500 μm, 400 μm, 300 μm or even lower.

Making large-size and/or thin glass sheets using the fusion down-draw isno easy undertaking, requiring the use of new generations of isopipeshaving significantly larger length. Over the years, experts such as thepresent inventors have gained insights into the many process parametersthat can impact the process stability during the forming process.Particularly, it was found that the formation of a stable, thin glassribbon over the large width of a large-generation isopipe may not beachieved reliably in a relatively short period of time within aneconomical process widow having a desirable yield without proper glassmelt flow velocity which can be quite different from the flow velocityfor smaller isopipes.

Therefore, there remains a need of an apparatus and method for makingglass sheets having a large size. The present invention satisfies thisand other needs.

SUMMARY

Several aspects of the present invention are disclosed herein. It is tobe understood that these aspects may or may not overlap with oneanother. Thus, part of one aspect may fall within the scope of anotheraspect, and vice versa.

Each aspect is illustrated by a number of embodiments, which, in turn,can include one or more specific embodiments. It is to be understoodthat the embodiments may or may not overlap with each other. Thus, partof one embodiment, or specific embodiments thereof, may or may not fallwithin the ambit of another embodiment, or specific embodiments thereof,and vice versa.

A first aspect of the present invention relates to a process for makinga glass sheet by an overflow process using a forming body comprising atrough-shaped part and a wedge-shaped part below the trough-shaped part,the trough-shaped part having a first trough side wall and a secondtrough side wall over a trough bottom surface defining an open channelhaving an open end, the open channel having a center plane, the firsttrough side wall having a first internal trough surface, a first troughtop surface and a first external trough side surface, the second troughside wall having a second internal trough surface, a second trough topsurface and a second external trough side surface, the wedge-shaped parthaving a first wedge side surface connecting with the first externaltrough side surface, and a second wedge side surface connecting with thesecond external trough side surface, the first and second wedge sidesurfaces sloping downwardly to join at a root line, the methodcomprising:

(i) delivering a stream of a molten glass via a closed channel into theopen channel of the trough-shaped part through the open end of the openchannel;

(ii) allowing the molten glass to flow over at least part of the firsttrough top surface, down along the first external trough side surface toform a first glass ribbon over the first external trough side surface;and

(iii) allowing the molten glass to flow over at least part of the secondtrough top surface, down along the second external trough side surfaceto form a second glass ribbon over the second external trough sidesurface; wherein

in step (i), the closed channel and the open channel are arranged suchthat the velocity distribution of the stream of the molten glass in avertical reference plane tangential to the center plane of the openchannel at a point where overflow starts on the first trough top surfaceis such that the average velocity of the molten glass in the top onefourth is higher than the average velocity in the bottom one fourthimmediately above the trough bottom surface.

In certain embodiments of the process of the first aspect of the presentinvention, the closed channel and the open channel are arranged suchthat the average velocity of the molten glass in the top one third ishigher than the average velocity in the bottom one third immediatelyabove the trough bottom surface.

In certain embodiments of the process of the first aspect of the presentinvention, the closed channel and the open channel are arranged suchthat the average velocity of the molten glass in the top one half ishigher than the average velocity in the bottom one half immediatelyabove the trough bottom surface.

In certain embodiments of the process of the first aspect of the presentinvention, the process further comprises, subsequent to steps (ii) and(iii), a step (iv), a step (v) and a step (vi) as follows:

(iv) allowing the first glass ribbon to further flow over the firstwedge side surface of the wedge-shaped part;

(v) allowing the second glass ribbon to further flow over the secondwedge side surface of the wedge-shaped part; and

(vi) allowing the first glass ribbon and the second glass ribbon to joinat the root line to form a single, third glass ribbon.

In certain embodiments of the process of the first aspect of the presentinvention, the process further comprises, subsequent to step (vi), astep (vii) as follows:

(vii) drawing the third glass ribbon below the root line.

In certain embodiments of the process of the first aspect of the presentinvention, steps (ii) and (iii) are carried out simultaneously.

In certain embodiments of the process of the first aspect of the presentinvention, steps (iv) and (v) are carried out simultaneously.

In certain embodiments of the process of the first aspect of the presentinvention, the center plane of the open channel is planar, and the openchannel is symmetrical with respect to the center plane.

In certain embodiments of the process of the first aspect of the presentinvention, the trough-shaped part is symmetrical with respect to thecenter plane of the open channel.

In certain embodiments of the process of the first aspect of the presentinvention, the wedge-shaped part is symmetrical with respect to thecenter plane of the open channel.

In certain embodiments of the process of the first aspect of the presentinvention, the trough-shaped part and the wedge-shaped part aresymmetrical with respect to the center plane of the open channel, andthe center plane is parallel to the gravity vector.

In certain embodiments of the process of the first aspect of the presentinvention, the trough-shaped part and the wedge-shaped part aresymmetrical with respect to a plane passing through the root line.

In certain embodiments of the process of the first aspect of the presentinvention, the first top trough surface and the second trough topsurface are planar and parallel to each other.

In certain embodiments of the process of the first aspect of the presentinvention, each of the first and second trough top surfacesindependently forms an angle alpha with respect to the center plane,same or different, wherein 75°≦alpha≦90°, in certain embodiments78°≦alpha≦90°, in certain embodiments 80°≦alpha≦90°, in certainembodiments 82°≦alpha≦90°, in certain embodiments 84°≦alpha≦90°, incertain embodiments 85°≦alpha≦90°, in certain other embodiments88°≦alpha≦90°.

In certain embodiments of the process of the first aspect of the presentinvention, the longitudinal axes of the first and second trough topsurfaces lie in a common plane, which intersects a reference planeperpendicular to the center plane of the open channel to form an anglegamma, wherein 0°≦gamma≦15°, in certain embodiments 0°≦gamma≦12°, incertain embodiments 0°≦gamma≦10°, in certain embodiments 0°≦gamma≦8°, incertain embodiments 0°≦gamma≦6°, in certain embodiments 0°≦gamma≦5°, incertain embodiments 0°≦gamma≦3°. The angle gamma is the downward orupward sloping angle of the first and second trough top surfaces withrespect to a horizontal plane (the reference plane) when the isopipe isplaced such that the center plane 199 is parallel to the gravity vector.It has been found that the present invention is particularlyadvantageous for quickly establishing a consistent glass flow on bothsides of the isopipe if the trough top surfaces slope downwardly with asmall angle gamma.

In certain embodiments of the process of the first aspect of the presentinvention, the trough bottom surface slopes upward from one end to theother end when the root line is held essentially perpendicular to thegravity vector.

In certain embodiments of the process of the first aspect of the presentinvention, the trough bottom surface slopes upward from the open end ofthe channel to the other end of the channel when the root line is heldessentially perpendicular to the gravity vector.

In certain embodiments of the process of the first aspect of the presentinvention, the trough bottom surface is essentially planar.

In certain embodiments of the process of the first aspect of the presentinvention, the trough bottom surface slopes upwards from the proximalend to the distal end of the open channel, and intersects with areference plane perpendicular to the center plane of the open channel toform an angle beta, wherein 0°≦beta≦10°, in certain embodiments0°≦beta≦80°, in certain embodiments 0°≦beta≦5°, in certain otherembodiments 0°≦beta≦3°.

In certain embodiments of the process of the first aspect of the presentinvention, the trough bottom surface slopes downwards from the proximalend to the distal end of the open channel, and intersects with areference plane perpendicular to the center plane of the open channel toform an angle beta2, wherein 0°≦beta2≦10°, in certain embodiments0°≦beta2≦8°, in certain embodiments 0°≦beta2≦5°, in certain otherembodiments 0°≦beta2≦3°

In certain embodiments of the process of the first aspect of the presentinvention, the open channel has a length LL from one end to the other,and a rectangular cross-section when intersected by a plane parallel tothe gravity vector and perpendicular to the center plane, saidcross-section having a width WW and a height HH.

In certain embodiments of the process of the first aspect of the presentinvention, LL≧1200 mm, in certain embodiments LL≧1500 mm, in certainembodiments LL≧2000 mm, in certain embodiments LL≧2500 mm, in certainother embodiments LL≧3000 mm.

In certain embodiments of the process of the first aspect of the presentinvention, the closed channel connecting with the trough-shaped partcomprises:

(A) a first part having a cross-section when intersected by a planeperpendicular to the center plane of the open channel having a firstaxis parallel to the gravity vector, and a second axis perpendicular tothe gravity vector; and

(B) a second transition closed channel fittingly connecting the firstpart with the open channel of the trough-shaped part.

In certain embodiments of the process of the first aspect of the presentinvention, the second axis of the first part is larger than the widthWW(IE) of a cross-section of the open channel of the trough-shaped partat the end of the open channel connecting with the second transitionclosed channel.

In certain embodiments of the process of the first aspect of the presentinvention, the ratio of WW(IEh) to the length of the second axis of thefirst part is from 0.5 to 0.95, in certain embodiments from 0.6 to 0.9,in certain embodiments from 0.6 to 0.8, in certain other embodimentsfrom 0.6 to 0.7.

In certain embodiments of the process of the first aspect of the presentinvention, the first axis of the first part is smaller than the heightHH(IE) of the rectangular cross-section of the open channel of thetrough-shaped part at the end of the open channel connecting with thesecond transition closed channel.

In certain embodiments of the process of the first aspect of the presentinvention, the ratio of the first axis of the cross-section of the firstpart to HH(IE) is from 0.5 to 0.95, in certain embodiments from 0.6 to0.9, in certain embodiments from 0.6 to 0.8, in certain otherembodiments from 0.6 to 0.7.

In certain embodiments of the process of the first aspect of the presentinvention, the ratio of the first axis to the second axis of the firstpart ranges from 1.0 to 3.0, in certain embodiments from 1.2 to 2.8, incertain other embodiments from 1.5 to 2.5, in certain other embodimentsfrom 1.7 to 2.1.

In certain embodiments of the process of the first aspect of the presentinvention, the second transition closed channel is symmetrical withrespect to the center plane of the open channel of the trough-shapedpart.

In certain embodiments of the process of the first aspect of the presentinvention, at least part of the first part is symmetrical with respectto the center plane of the open channel of the trough-shaped part.

In certain embodiments of the process of the first aspect of the presentinvention, the distance from the center of the cross-section of the endof the first part connecting with an end of the second transition closedchannel to a plane perpendicular to the gravity vector and tangential toa bottom line of the open end of the open channel is DT1;

the distance from the free surface of the molten glass abutting the endof the open channel to the plane perpendicular to the gravity vector andtangential to a bottom line of the open end of the open channel is DT2;and

DT1/DT2≧0.50; in certain embodiments DT1/DT2≧0.60; in certainembodiments DT1/DT2≧0.70; in certain embodiments DT1/DT2≧0.80; incertain embodiments DT1/DT2≧0.90.

In certain embodiments of the process of the first aspect of the presentinvention, the cross-section of the first part is elliptical.

In certain embodiments of the process of the first aspect of the presentinvention, the ratio of the first axis to the second axis of the firstpart ranges from 1.0 to 3.0, in certain embodiments from 1.2 to 2.8, incertain other embodiments from 1.5 to 2.5, in certain other embodimentsfrom 1.7 to 2.1.

In certain embodiments of the process of the first aspect of the presentinvention, the velocity distribution of the stream of molten glassimmediately before exiting the end of the first part is symmetrical withrespect to the center plane of the open channel.

In certain embodiments of the process of the first aspect of the presentinvention, the velocity distribution of the stream of molten glassimmediately before existing the end of the first part is symmetricalwith respect to a plane perpendicular to the gravity vector and passingthrough the second axis of the cross-section of the first part.

A second aspect of the present invention is directed to an apparatus formaking a glass sheet comprising:

(a) a forming body comprising a trough-shaped part over a wedge-shapedpart, the trough-shaped part having a first trough side wall and asecond trough side wall over a trough bottom surface defining an openchannel having art open end, the open channel having a center plane, thefirst trough side wall having a first internal trough surface, a firsttrough top surface and a first external trough side surface, the secondtrough side wall having a second internal trough surface, a secondtrough top surface and a second external trough side surface, thewedge-shaped part having a first wedge side surface connecting with thefirst external trough side surface, a second wedge side surfaceconnecting with the second external trough side surface, the first andsecond wedge side surfaces sloping downwardly to join at a root line;and

(b) a tube defining a closed channel connecting with the open channel ofthe trough-shaped part through the open end of the open channel, thetube comprising:

(b1) a first part having a cross-section when intersected by a planeperpendicular to the center plane having a first axis parallel to thegravity vector if the center plane is parallel to the gravity vector,and a second axis perpendicular to the first axis; and

(b2) a second transition closed channel fittingly connecting the firstpart with the open channel of the trough-shaped part;

wherein:

the distance from the center of the cross-section of the end of thefirst part connecting with an end of the second transition closedchannel to a plane perpendicular to the first axis and tangential to abottom line of the open end of the open channel is DT1;

the distance from the first trough top surface at the end of the openchannel to the plane perpendicular to the first axis and tangential to abottom line of the open end of the open channel is DT2; and

DT1/DT2≧0.50; in certain embodiments DT1/DT2≧0.60; in certainembodiments DT1/DT2≧0.70; in certain embodiments DT1/DT2≧0.80; incertain embodiments DT1/DT2≧0.90.

In certain embodiments of the apparatus of the second aspect of thepresent invention, the cross-section of the first part is elliptical.

In certain embodiments of the apparatus of the second aspect of thepresent invention, the ratio of the first axis to the second axis of thefirst part ranges from 1.0 to 3.0, in certain embodiments from 1.2 to2.8, in certain other embodiments from 1.5 to 2.5, in certain otherembodiments from 1.7 to 2.1.

In certain embodiments of the apparatus of the second aspect of thepresent invention, the first part of the tube defining the closedchannel has a cylindrical cross-section when intersected by a planeperpendicular to the root line.

In certain embodiments of the apparatus of the second aspect of thepresent invention, the root line is perpendicular to the gravity vector.

In certain embodiments of the apparatus of the second aspect of thepresent invention, the second axis of the first part is larger than thewidth WW(IE) of a cross-section of the open channel of the trough-shapedpart at the end of the open channel connecting with the secondtransition closed channel.

In certain embodiments of the apparatus of the second aspect of thepresent invention, the ratio of WW(IE) to the length of the second axisof the first part is from 0.5 to 0.95, in certain embodiments from 0.6to 0.9, in certain embodiments from 0.6 to 0.8, in certain otherembodiments from 0.6 to 0.7.

In certain embodiments of the apparatus of the second aspect of thepresent invention, the first axis of the first part is smaller than theheight HH(IE) of the cross-section of the open channel of thetrough-shaped part at the end of the open channel connecting with thesecond transition closed channel.

In certain embodiments of the apparatus of the second aspect of thepresent invention, the ratio of the first axis to HH(IE) is from 0.5 to0.95, in certain embodiments from 0.6 to 0.9, in certain embodimentsfrom 0.6 to 0.8, in certain other embodiments from 0.6 to 0.7.

In certain embodiments of the apparatus of the second aspect of thepresent invention, the second transition closed channel is symmetricalwith respect to the center plane of the open channel of thetrough-shaped part.

In certain embodiments of the apparatus of the second aspect of thepresent invention, at least part of the first part is symmetrical withrespect to the center plane of the open channel of the trough-shapedpart.

In certain embodiments of the process of the first aspect of the presentinvention, the open channel of the trough-shaped part of the isopipe hasa length LL from one end to the other, wherein LL≧1200 mm, in certainembodiments LL≧1500 mm, in certain embodiments LL≧2000 mm, in certainembodiments LL≧2500 mm, in certain other embodiments LL≧3000 mm.

One or more embodiments and/or aspects of the present disclosure haveone or more of the following advantages. First, the closed channeldesign of the glass inlet pipe allows for a glass melt velocity profilehaving a higher average velocity in the vicinity of the surface than anaverage velocity in the vicinity of the bottom, resulting in reliableformation of a glass ribbon over the entire weir top surfaces and sidesurfaces. Second, the higher surface velocity, especially in thevicinity of the overflow starting position, resulting from the closedchannel design of the invention allows for the formation of a glassribbon over the weir surfaces and side surfaces with a more desired massdistribution along the length of the weirs suitable for making a glasssheet with high thickness uniformity by the overflow fusion down-drawprocess. Third, the apparatus and the method of the present inventioncan be particularly advantageous for making large-size glass sheetshaving a width of at least 2000 mm, especially those with a width of atleast 3000 mm. The inverted design of the present invention can be usedto replace previous equipment without taking up significant amountadditional space, making retrofitting relatively easy.

Additional features and advantages of the invention will be set forth inthe detailed description which follows, and in part will be readilyapparent to those skilled in the art from the description or recognizedby practicing the invention as described in the written description andclaims hereof, as well as the appended drawings.

It is to be understood that the foregoing general description and thefollowing detailed description are merely exemplary of the invention,and are intended to provide an overview or framework to understandingthe nature and character of the invention as it is claimed.

The accompanying drawings are included to provide a furtherunderstanding of the invention, and are incorporated in and constitute apart of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings:

FIG. 1 is a schematic drawing showing an isopipe operating in anoverflow fusion down-draw process for making a glass ribbon.

FIG. 2 is a schematic drawing showing a cross-section of the isopipeillustrated in FIG. 1.

FIG. 3 is a schematic drawing showing a closed channel coupled with anisopipe at the inlet end.

FIG. 4 is a schematic drawing showing a side view of part of the closedchannel shown in FIG. 3.

FIG. 5 is a schematic drawing showing the end view of the closed channelshown in FIG. 3.

FIG. 6 is a schematic drawing showing a closed channel coupled with anisopipe at the inlet end in a manner different from that of FIG. 3.

FIG. 7 is a schematic drawing showing a side view of part of the closedchannel shown in FIG. 6.

FIG. 8 is a schematic drawing showing the end view of the closed channelshown in FIG. 6.

FIG. 9 is a schematic illustration of a sheet glass-making system usingan overflow down-draw process.

FIG. 10 shows a partial enlarged view of a corner of the isopipe inoperation illustrated in FIG. 2 showing glass melt overflowing a secondtrough top surface.

FIG. 11 is a diagram showing calculated surface velocity and thicknessprofiles of the glass melt overflowing the isopipe illustrated in FIG.10 using the inlet assembly of FIGS. 3 and 6, respectively.

FIG. 12 is a diagram showing glass melt surface velocity increase andthickness increase by using the FIG. 6 set-up over using the FIG. 3set-up.

DETAILED DESCRIPTION

Unless otherwise indicated, all numbers such as those expressing weightpercents and mole percents of ingredients, dimensions, and values forcertain physical properties used in the specification and claims are tobe understood as being modified in all instances by the term “about.” Itshould also be understood that the precise numerical values used in thespecification and claims form additional embodiments of the invention.Efforts have been made to ensure the accuracy of the numerical valuesdisclosed in the Examples. Any measured numerical value, however, caninherently contain certain errors resulting from the standard deviationfound in its respective measuring technique.

As used herein, in describing and claiming the present invention, theuse of the indefinite article “a” or “an” means “at least one,” andshould not be limited to “only one” unless explicitly indicated to thecontrary. Thus, for example, reference to “a side surface” includesembodiments having one, two or more such side surfaces, unless thecontext clearly indicates otherwise.

The overflow down-draw process for making a sheet glass is described inWO03/014032, WO05/081888, and the like, the relevant contents thereofare incorporated herein by reference in their entirety.

FIGS. 1 and 2 schematically illustrate an isopipe assembly 100 duringnormal operation. The isopipe comprises an upper trough-shaped part 102and a lower wedge-shaped part 104, which, in combination, form a unitaryforming body 100. The trough-shaped part comprises a first trough sidewall having a first internal trough side surface 121, a second troughside wall having a second internal trough side surface 123, and a troughbottom surface 122, which together define an open channel (also called“trough”) 103 into which glass melt is introduced, typically through anopen end thereof. The glass melt is allowed to flow over the firsttrough top surface 125 of the first trough wall and the second troughtop surface 127 of the second trough wall as two separate glass ribbons,down along a first external trough side surface 129 and a secondexternal trough side surface 131, and further down along a sloping firstwedge side surface 133 connecting with the first external trough sidesurface 129, and a sloping second wedge side surface 135 connecting withthe second external trough side surface 131. At the root 109 where thetwo wedge side surfaces 133 and 135 join, the two glass ribbons fuse toform a unitary glass ribbon 111, which is further drawn down in thedirection 113 to a desired thickness, cooled down to elastic state, andthen cut into individual glass sheet pieces with desired size. For thepurpose of convenient description, a virtual plane 199 having thesmallest cumulative difference in distances to (I) the first internaltrough side surface 121 of the first trough wall and to (II) the secondinternal trough side surface 123 of the second trough wall is defined asthe center plane of the open channel (trough) 103. Thus, if the openchannel 103 is symmetrical with respect to a plane passing thecenterline, the center plane 199 would be the plane with respect towhich the two sides of the open channel 103 are symmetrical. Desirably,both the trough-shaped part and the wedge-shaped part are symmetricalwith respect to the center plane 199 of the open channel. In suchscenario, the center plane 199 would also pass the root line 109 of theisopipe.

In a desired process, the glass melt should overflow the first andsecond trough top surfaces 125 and 127 and cover them continuously toform a smooth and continuous glass ribbon. Likewise, the glass ribbonsflowing down the external side surfaces 129, 131, 133, 135 of theisopipe should desirably cover the entire side surfaces (subject tophysical restrictions by other isopipe accessories, such as the end-capsand edge directors, and the like) without significant thicknessvariation from one end of the isopipe to the other, except in the endsections where larger or smaller thicknesses than the middle may beaccepted. Desirably, the glass melt flow in the two ribbons isconsistent over an extended period of time so that a glass sheet can bereliably produced at the bottom or the draw. At the beginning of aforming campaign, it may take some time for the glass flows to establishfull, stable and consistent ribbons with desirable thickness and flowrate. To increase the overall yield of the glass during a full campaign,it is highly desirable that the initial period required to establishsuch stable glass ribbons be as short as possible. The flow rate anddistribution thereof of the glass melt along the full length of thefirst and second trough top surfaces affect the thickness and thicknessvariation of the final glass sheet to be produced at the bottom of thedraw.

As shown in FIG. 2, the isopipe trough 103 in this embodiment has arectangular cross-section when intersected by a plane substantiallyperpendicular to the longitudinal axis thereof. Thus, the trough sidewalls are substantially vertical and the bottom surface of the trough issubstantially planar at least partly. The trough, and the isopipe havean open, proximal end through which glass melt is introduced into thetrough through an inlet tube typically in the form of a closed channelcoupled with the open end of the trough, and a distal end which istypically closed.

In the past, when smaller generation isopipes having a length of lessthan 2000 mm were used to make glass sheets having a relatively smallsheet width, the coupling of the inlet tube typically takes the form asillustrated in FIGS. 3, 4 and 5. The inlet tube typically has acylindrical section 301 with a center axis 307 and a transition part 303having a circular end 305 welded to end of the cylindrical section 301,and a rectangular end coupled to the rectangular open end of the trough.The glass melt, once it fills the trough completely, will flow over thetop trough surface 313, establish a stream of glass melt having a topfree surface 309 due to the overall head of the glass melt as providedby the upstream process. This inlet coupling design results in a glassmelt velocity profile that can satisfy the needs of manufacture of glasssheets with a width of less than 2000 mm.

Recently, the present inventors found that the conventional design ofFIGS. 3, 4 and 5 do not meet the needs of forming glass sheets usingisopipes having a length of over 3000 mm. Continuous and consistentglass ribbons were difficult to establish over the trough side wall topsurfaces and the side surfaces of the isopipe for the purpose of makinga glass sheet below the isopipe having a thickness and thicknessvariation profile meeting the requirements. An inlet pipe re-design wasrequired.

Surprisingly, the present inventors found that by using an inlet pipedesign having a closed channel illustrated in FIGS. 6, 7 and 8, stable,consistent and reliable glass ribbons can be established over a longisopipe having a length of over 3000 mm, and the speed of establishing astable forming process was quite acceptable. Because this inlet pipecoupling design is substantially an inverted version of what isillustrated in FIGS. 3, 4 and 5, it is sometimes called “inverted inletdesign.”

In-depth study, including mathematical modeling and simulation, oilmodeling using oil having rheological properties similar to the glassmelt to be handled during normal operation, found that the inverteddesign of FIGS. 6, 7 and 8 resulted in a significantly different glassmelt velocity distribution from that of FIGS. 3, 4 and 5, which isparticularly beneficial for quickly establishing a glass ribbon over theisopipe surfaces. Specifically, a salient and desirable trait of theglass melt flow is: the velocity distribution of the stream of themolten glass in a vertical plane tangential to the center plane of theopen channel at a point where overflow starts on the first and secondtrough top surfaces is such that the velocity of the molten glass in thetop one fourth from the free surface is higher than the velocity of themolten glass in the bottom one fourth immediately above the troughbottom surface. The higher velocity at the top portion, especially thefree surface of the glass melt than in the bottom region was found to beparticularly beneficial for the quick establishment of a stable andcontinuous glass flow over the trough side top surfaces and the sidesurfaces of the isopipe with desirable mass distribution satisfying theneeds of manufacture of a glass sheet for LCD substrates. The presentinventors believe that while this velocity distribution is particularlyadvantageous for large-size isopipes and may be required for thosehaving a length of over 3000 mm, it can be advantageously applied tosmaller generation isopipes, such as those having a length of below 3000mm, especially those having a significant length of at least 2000 mm.

In certain embodiments of the process of the present invention, it ishighly desired that the glass ribbon flowing downward on the two sidesurfaces 129, 131 of the trough-shaped part and the two sides surfaces133, 135 of the wedge-shaped part are substantially symmetrical, i.e.,they have substantially the same width from one end of the isopipe tothe other, and substantially the same thickness distribution from thetop side wall surfaces to the root of the isopipe. The glass ribbons mayhave different thickness from the top to the bottom of the isopipe ateach side as the temperature and viscosity of the glass melt changesfrom the top to the bottom. When the two glass ribbons flowing downalong the two side surfaces join at the root, the inner surfacescontacting the side surfaces of the isopipe fused into the bulk of theglass ribbon which is drawn down below the isopipe, leaving the twoexternal surfaces of the glass ribbons to be continue to be exposed tothe air and without contact any solid surface, thereby preserving apristine surface quality, which will be carried into the end glass sheetproducts.

Needless to say, to establish substantially symmetrical glass ribbonsover the side surfaces 129, 131, 133 and 135 as discussed supra, theflow of glass melt over the weir surfaces of the isopipe (i.e., thefirst trough top surface and the second trough top surface) and alongthe side surfaces 129, 131, 133 and 135 need to take place substantiallysimultaneously, and with substantially the same velocity profile. Tothat end, it is highly desired that all of the following are symmetricalwith respect to the center plane 199 of the open channel of the trough103: (i) the open channel of the trough 103; (ii) the first and secondinternal trough side surfaces 121 and 123; (iii) the first and secondexternal trough side surfaces 129 and 131; and (iv) the first and secondwedge side surfaces 133 and 135 of the wedge-shaped part. In theseembodiments, it is desired that the influence of external forces, suchas gravity, to the shape and geometry change of the isopipe, and to theflow of the glass melt along both sides of the isopipe, be symmetricalas well. To that end, it is desired that the isopipe be placed in amanner such that the center plane 199 of the open channel be parallel tothe gravity vector, and that root line is within the center plane 199.

The first and second trough top surfaces 125 and 127 may besubstantially planar, even though curved surfaces may be used. Likewise,side surfaces 129, 131, 133 and 135 may be substantially planar, eventhough curved surfaces may be used as well. The first and second troughtop surfaces 125 and 127 may be substantially perpendicular to thecenter plane 199, or form an angle alpha with respect to the samereference plane. Nonetheless, it is desired that wherein 0°≦alpha≦10°,in certain embodiments 82°≦alpha≦90°, in certain embodiments84°≦alpha≦90°, in certain embodiments 85°≦alpha≦90°. The longitudinalaxes of the first and second trough top surfaces 125 and 127 desirablylie in a common plane, which intersects a reference plane perpendicularto the center plane 199 of the open channel to form an angle gamma,where 0°≦gamma≦10°, in certain embodiments alpha 0°≦gamma≦8°, in certainembodiments 0°≦gamma≦6°, in certain embodiments 0°≦gamma≦5°, in certainembodiments 0°≦gamma≦3°. The angle gamma is the downward sloping angleof first and second trough top surfaces with respect to a horizontalplane (the reference plane) when the isopipe is placed such that thecenter plane 199 is parallel to the gravity vector. It has been foundthat the present invention is particularly advantageous for quicklyestablishing a stable and consistent glass flow on both sides of theisopipe if the trough top surfaces slope downwardly with a small anglegamma.

The trough bottom surface 122 can be a flat plane or a curved plane.Regardless, in order to achieve symmetrical glass flow on both sides ofthe isopipe, it is highly desired that the trough bottom surface 122 besubstantially symmetrical with respect to the center lane 199 of theopen channel 103 as well. The trough bottom surface 122 can be planar orcurved from one side wall to the other, and can be planar or curved fromone end of the channel to the other. In one particularly advantageousembodiment illustrated in FIG. 1, the trough bottom surface 122 slopesupwards from the proximal end (inlet end) to the distal end, thusintersecting a reference plane perpendicular to the center plane 199 toform an angle beta. It is desired that 0°≦beta≦10°, in certainembodiments 0°≦beta≦80°, in certain embodiments 0°≦beta≦5°, in certainembodiments 0°≦beta≦3°. In another embodiment, as illustrated in FIGS. 3and 6, the trough bottom surface 122 slopes downwardly from the proximalend to the distal end, thus intersecting a reference plane perpendicularto the center plane 199 to form an angel beta2. It is desired that0°≦beta2≦10°, in certain embodiments 0°≦beta2≦8°, in certain embodiments0°≦beta2≦6°, in certain embodiments 0°≦beta2≦5°. If the first and secondtrough top surfaces slope downwardly from the proximal end to the distalend, it is desired that the bottom surface 122 slopes downwardly fromthe proximal end to the distal end as well, so that a stable andconsistent flow can be established relatively fast on both sides of theisopipe.

Thus, the open channel 103 of the isopipe can have a length LL from theproximal end to the distal end, and a rectangular cross-section whenintersected by a reference plane perpendicular to the center plane 199.The cross-section can have a height HH in the direction of the gravityvector when the center plane 199 is placed to be parallel to the gravityvector, and a width WW. As described supra, the present invention isparticularly advantageous for use with isopipes having a long lengthsuitable for making large size glass sheets. For example, it isadvantageous that in certain embodiments of the process of the presentinvention, LL≧2000 mm, in certain embodiments LL≧2500 mm, in certainother embodiments LL≧3000 mm. As mentioned supra, the present inventionprocess may be advantageously used for isopipes having an LL less than2000 mm as well.

In a glass sheet-making system 900 schematically illustrated in FIG. 9involving using overflow fusion down-draw forming, a glass melt 926 istypically formed by melting raw materials 912 in a glass melting tank910, which is then conditioned to reduce or remove inhomogeneousportions such as cord and gas bubbles, e.g., in a finer tube 915 and astirrer 920 connected by a tube 922. The glass melt is then deliveredthrough a channel 927 to a bowl 925, then through a down-comer tube 930into an inlet tube assembly 932 comprising a vertical part and ahorizontal part. The horizontal part 936 is coupled to the open end ofthe open channel 937 at the proximal end of an isopipe. Once the glassmelt fills the open channel, it is allowed to flow over both side walls(called weirs) of the open channel 937, down along the side surfaces ofthe isopipe as two glass ribbons 938, which join at the root 939 of theisopipe to form a unitary glass ribbon 926, which is then drawn down by,e.g., pulling rolls 940 inside the fusion draw machine (FDM) 940, andcooled down to an elastic glass ribbon 905, which will be subsequentlycut into separate glass sheets.

The present invention involves the improvement to the horizontal part ofthe inlet tube assembly. As mentioned supra, FIGS. 3, 4 and 5schematically illustrate the set-up of an inlet tube assembly usedpreviously for smaller generation isopipes, such as those having a LLless than 2000 mm. the horizontal part of the inlet tube assemblycomprises an elliptic cylindrical part 301 having a first axis in thedirection of the vertical line 503, which is typically parallel to thegravity vector, and a second axis in the direction of a the horizontalline 501. The horizontal part of the inlet tube assembly furthercomprises a transition part 303 coupling the elliptic cylindrical part301 to the open end of the open channel 305. Thus, the transition partcomprises an elliptic cylindrical end fittingly connected to the end of301 and a rectangular end fittingly connected to the proximal end of theopen channel of the trough of the isopipe. The design of FIG. 3 resultsin the longitudinal axis 307 of the elliptic cylindrical part 301 beinglower than the center of the rectangular end of 303. The glass melt iscontained by an edge guide (not shown) and is not allowed to overflowthe first trough top surface 313 until it reaches the location 311,where the edge guide ends. As is shown in FIG. 5, the second axis of theelliptic cylindrical portion is larger than the width of the transitionportion in the direction of line 501. Therefore, the glass flow iscompressed in width but enlarged in height when it exits the ellipticcylindrical part and enters into the transition part. As FIG. 3 shows,this inlet assembly arrangement can achieve overflow of the glass meltat the overflow starting position 311. However, it was found that thisarrangement was not acceptable for larger-size isopipes having a lengthof over 3000 mm, as discussed infra.

As a result of in-depth research and development effort for theoperation of large-size isopipe, the present inventors came up with aninverted design of the horizontal part of the inlet assembly, anembodiment of which is illustrated in FIG. 6. Similar to the design ofFIG. 3, the horizontal part of the inlet assembly includes a first part607 having a longitudinal axis 607, and a transition part 603 with oneend connected with the first part 601, and a second end fittinglyconnected with the proximal end of the open channel of the trough of theisopipe. In the embodiment shown in FIGS. 6, 7 and 8, the first part 601has an elliptic cylindrical shape, i.e., an elliptical cross-section,and the transition part has an elliptic cylindrical end connected withthe first part 601, and a rectangular end connected with the proximalend of the open channel of the trough of the isopipe. It should beunderstood that other cross-section of the first part, and thereforeother cross-section of the transition part, may be used. For example,the first part may have a cross-section with a rectangular or squareshape, a pear shape, a heart shape, or other shape. The first axis ofthe cross-section of the first part is its vertical center line, and thesecond axis of the cross-section of the first part is its horizontalcenter line. The center of the cross-section is the cross point of thefirst and second axes. It is desired that the cross-section of the firstpart is substantially symmetric with respect to the first axis thereof.Due to the inverted design, the longitudinal axis 607 of 601 is higherthan the center of the rectangular end of the transition part 603. Thecenter of the rectangular end is the cross-point of the diagonal linesof the rectangular cross-section. Likewise, the glass melt is restrictedby an edge guide (not shown) and is not allowed to overflow the firsttrough top surface 613 until the location 611. In addition, as shown inFIGS. 7 and 8, the first part 601 has a cross-section having a firstaxis in the direction of 803 (the direction of the gravity vector incertain embodiments) and a second axis in the direction 803, which isperpendicular to 801. In the embodiment as shown in FIGS. 7 and 8, thesecond axis of the first part 601 is larger than the width of therectangular end of the transition part 603, resulting in a glass flowthat is compressed in the width direction and enlarged in the heightdirection. In a particularly desirable embodiment, the first part of thehorizontal part of the inlet assembly takes the shape of a cylinder atleast in the segment directly connected to the transition closedchannel. As a result of this inverted set-up, the velocity of the glassmelt in the surface region is higher than in the bottom region, and thevelocity of the glass melt in the surface in the region proximate to theoverflow starting point is higher than the embodiment shown in FIGS. 3,4 and 5, assuming all other conditions being equal. While the embodimentshown in FIGS. 6, 7 and 8 have a second axis larger than the widthWW(IE) of the cross-section of the open channel at the proximal end ofthe isopipe, such relationship is not required. In certain embodiments,the second axis of the first part may be smaller than WW(IE).Nonetheless, it is advantageous to establish a reliable glass streamcovering the intended areas of the first and second trough top surfacesand the side surfaces of the isopipe where the ratio of WW(IE) to thelength of the second axis of the first part is from 0.5 to 0.95, incertain embodiments from 0.6 to 0.9, in certain embodiments from 0.6 to0.8, in certain other embodiments from 0.6 to 0.7.

It is highly desirable that the first axis of the first part is smallerthan the height HH(IE) of the rectangular cross-section of the openchannel of the trough-shaped part at the end of the open channelconnecting with the second transition closed channel. This would resultin the enlargement of the glass flow in the direction in the verticaldirection when the glass melt flows from the first part to thetransition part. The enlargement allows the formation of a reliablestream of glass over the weir surfaces and the isopipe side surfaces. Incertain embodiments, the ratio of the first axis of the cross-section ofthe first part to HH(IE) is from 0.5 to 0.95, in certain embodimentsfrom 0.6 to 0.9, in certain embodiments from 0.6 to 0.8, in certainother embodiments from 0.6 to 0.7.

Likewise, in order to obtain a symmetrical glass stream over both sidesof the isopipe, it is highly desired that the placement of thetransition closed channel is such that it is symmetrical with respect tothe center plane 199 of the open channel of the trough of the isopipe.It is further desired that in certain embodiment at least part of thecylindrical closed channel connected with the transition closed channelis located such that it is symmetrical with respect to the center planeof the open channel of the isopipe.

In certain embodiments, the distance from the center of thecross-section of the end of the first part connecting with an end of thesecond transition closed channel to a plane perpendicular to the gravityvector and tangential to a bottom line of the open end of the openchannel is DT1; the distance from the free surface of the molten glassabutting the end of the open channel to the plane perpendicular to thegravity vector and tangential to a bottom line of the open end of theopen channel is DT2; and DT1/DT2≧0.50; in certain embodimentsDT1/DT2≧0.60; in certain embodiments DT1/DT2≧0.70; in certainembodiments DT1/DT2≧0.80; in certain embodiments DT1/DT2≧0.90. Thisarrangement allows for the establishment of a faster surface regionglass melt velocity relative to the bottom region glass melt velocity.In addition, this apparatus set-up would result in faster and morestable establishment of a glass ribbon flowing over the weir surfaceswith a more uniform thickness across the width of the open channel fromthe proximal end to the distal end.

To obtain symmetrical glass flow on both sides of the isopipe using theinvention of the present invention, it is highly desirable that thevelocity distribution of the stream of molten glass immediately beforeexiting the end of the first part is symmetrical with respect to thecenter plane of the open channel. In certain embodiments, it is evendesirable that the velocity distribution of the stream of molten glassimmediately before exiting the end of the first part is symmetrical withrespect to a plane perpendicular to the gravity vector and passingthrough the second axis of the cross-section of the first part.

A second aspect of the present invention is an apparatus for making aglass sheet comprising:

(a) a forming body comprising a trough-shaped part over a wedge-shapedpart, the trough-shaped part having a first trough side wall and asecond trough side wall over a trough bottom surface defining an openchannel having an open end, the open channel having a center plane, thefirst trough side wall having a first internal trough surface, a firsttrough top surface and a first external trough side surface, the secondtrough side wall having a second internal trough surface, a secondtrough top surface and a second external trough side surface, thewedge-shaped part having a first wedge side surface connecting with thefirst external trough side surface, a second wedge side surfaceconnecting with the second external trough side surface, the first andsecond wedge side surfaces sloping downwardly to join at a root line;and

(b) a tube defining a closed channel connecting with the open channel ofthe trough-shaped part through the open end of the open channel, thetube comprising:

(b1) a first part having a cross-section when intersected by a planeperpendicular to the center plane having a first axis parallel to thegravity vector if the center plane is parallel to the gravity vector,and a second axis perpendicular to the first axis; and

(b2) a second transition closed channel fittingly connecting the firstpart with the open channel of the trough-shaped part;

wherein:

the distance from the center of the cross-section of the end of thefirst part connecting with an end of the second transition closedchannel to a plane perpendicular to the first axis and tangential to abottom line of the open end of the open channel is DT1;

the distance from the first trough top surface at the end of the openchannel to the plane perpendicular to the first axis and tangential to abottom line of the open end of the open channel is DT2; and

DT1/DT2≧0.50; in certain embodiments DT1/DT2≧0.60; in certainembodiments DT1/DT2≧0.70; in certain embodiments DT1/DT2≧0.80; incertain embodiments DT1/DT2≧0.90.

Detailed description of the various embodiments of the apparatus of thepresent invention can be found in the above description of the process.

Simulation of the glass melt flow over an isopipe having a length ofover 3000 mm was conducted using the apparatus set-up of FIG. 3 and FIG.6, respectively. The magnitude of the velocity vector of the glass meltat the free surface (VFS) above the second trough top surface and thethickness of the glass melt (TH) were calculated using a fluid dynamicsmodel assuming that the conditions were identical for both set-upsexcept for the configuration of inlet assembly as shown in FIGS. 3 and6. Although VFS is shown to be substantially perpendicular to the centerplane 199 in FIG. 10, it is not required to be so. In FIG. 11, the soliddiamond-shaped data series are the VFS of the glass melt using theset-up of FIG. 6; the solid triangle-shaped data series are the VFS ofthe glass melt using the set-up of FIG. 3; the hollow square-shaped dataseries 1105 are the thickness TH of the glass melt using the set-up ofFIG. 6; and the hollow triangle-shaped data series 1107 are thethickness TH of the glass melt using the set-up of FIG. 3. The leftvertical axis shows the VFS; the right vertical axis shows the thicknessTH scale; and the horizontal axis shows the distance from the pointwhere the overflow of the glass melt starts along the top second troughsurface 127. The same data are presented in FIG. 12 in a differentmanner, where the solid diamond-shaped data series 1201 shows thepercentage increase of VFS by using the FIG. 6 set-up compared to usingthe FIG. 3 set-up (VI, the scale of which is shown on the left verticalaxis); and the hollow square-shaped data series 1203 show the percentagechange of glass melt thickness (THI, the scale of which is shown in theright vertical axis); and the horizontal axis show the distance from thelocation where glass melt overflow starts along the second trough topsurface 127.

Data in FIGS. 11 and 12 clearly show the following. The FIG. 6 set-up,an embodiment of the present invention, resulted in a much more uniformsurface velocity and a much more uniform thickness of the glass meltacross the length of the second trough top surface 127. Using the set-upof FIG. 3 resulted in both low surface glass melt velocity and glassmelt thickness in area close to the overflow starting point. Using theset-up of FIG. 6 greatly increased the surface glass melt velocity (upto 12%) and initial glass melt thickness (up to 4%) in locations closeto the overflow starting point. Therefore, a glass ribbon having moreuniform thickness can be established using the set-up of FIG. 6 thanusing the set-up of FIG. 3. Moreover, the more uniform velocity andthickness profiles of the glass stream over the weir top surfaces leadto a more reliable and consistent glass sheet drawing process.

It will be apparent to those skilled in the art that variousmodifications and alterations can be made to the present inventionwithout departing from the scope and spirit of the invention. Thus, itis intended that the present invention cover the modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

What is claimed is:
 1. An apparatus for making a glass sheet comprising:(a) a forming body comprising a trough-shaped part over a wedge-shapedpart, the trough-shaped part having a first trough side wall and asecond trough side wall over a trough bottom surface defining an openchannel having an open end, the open channel having a center plane, thefirst trough side wall having a first internal trough surface, a firsttrough top surface and a first external trough side surface, the secondtrough side wall having a second internal trough surface, a secondtrough top surface and a second external trough side surface, thewedge-shaped part having a first wedge side surface connecting with thefirst external trough side surface and a second wedge side surfaceconnecting with the second external trough side surface, the first andsecond wedge side surfaces sloping downwardly to join at a root line;and (b) a tube defining a closed channel connecting with the openchannel of the trough-shaped part through the open end of the openchannel, the tube comprising: (b1) a first part, which is a closedchannel, and (b2) a second part, which is a transition closed channel,said second part fittingly connecting the first part with the openchannel of the trough-shaped part; wherein: said first part has a firstpart cross-section in a plane perpendicular to the center plane of theopen channel, said first part cross-section (i) having a center and (ii)being located at the end of the first part where the first part connectswith the second part; the open end of the open channel has an open endcross-section which has a bottom line; the distance from the center ofsaid first part cross-section to a plane which is perpendicular to thegravity vector and contains said bottom line is DT1; the distance fromthe first trough top surface at the open end of the open channel to saidplane which is perpendicular to the gravity vector and contains saidbottom line is DT2; and DT1/DT2≧0.50.
 2. An apparatus according to claim1, wherein said first part cross-section is elliptical.
 3. An apparatusaccording to claim 1, wherein the first part cross-section has avertical center line and a length along said vertical center line; thefirst part cross-section has a horizontal center line and a length alongsaid horizontal center line; and the ratio of the length along thevertical center line to the length along the horizontal center lineranges from 1.0 to 3.0.
 4. An apparatus according to claim 1, whereinthe first part cross-section has a horizontal center line and a lengthalong said horizontal center line; and said length along said horizontalcenter line is larger than the width WW(IE) of a cross-section of theopen channel of the trough-shaped part, said cross-section of the openchannel being at the end of the open channel where the open end connectswith the second part of the closed channel.
 5. An apparatus according toclaim 4, wherein the ratio of WW(IE) to said length along saidhorizontal center line is from 0.5 to 0.95.
 6. An apparatus according toclaim 1, wherein the first part cross-section has a vertical center lineand a length along said vertical center line; the open channel of thetrough-shaped part has a rectangular cross-section at its end where itconnects with the second part; said rectangular cross-section has aheight HH(IE); the length along said vertical center line is smallerthan HH(IE).
 7. An apparatus according to claim 6, wherein the ratio ofthe length along said vertical center line to HH(IE) is from 0.5 to0.95.
 8. An apparatus according to claim 1, wherein the second part issymmetrical with respect to the center plane.
 9. An apparatus accordingto claim 1, wherein at least part of the first part is symmetrical withrespect to the center plane.
 10. An apparatus according to claim 1,wherein the open channel has a length LL, LL≧1200 mm.